Apparatus and methods of attaching panels to support structures

ABSTRACT

Apparatus and methods for attaching wall panels to support structures are disclosed. In one embodiment, an apparatus includes a first member and a second member. The first member is coupled to the support structure and has a first elongated coupling member. The second member has a head portion and a base portion. The head portion has at least one slot disposed therein that is adapted to receive an edge portion of the panel. The base portion includes a second elongated coupling member that is adapted to be coupled to the first elongated coupling member.

FIELD OF THE INVENTION

[0001] The present disclosure relates to attachment of interior wallpanels to support structures and, more specifically, to attachment ofinterior wall panels within aircraft.

BACKGROUND OF THE INVENTION

[0002] Many contemporary vehicles, especially those used for thetransportation of passengers, are equipped with interior wall panelsthat are attached to a frame or other support structure of the vehicle.For example, the passenger compartments of most modern aircraft, trains,and buses are equipped with interior wall panels. Interior wall panelsmay improve the passenger's enjoyment by reducing noise or improving theaesthetic quality of the passenger's environment.

[0003]FIG. 1 is an isometric view of an aircraft interior 10 prior toinstallation of wall panels 12 (not shown) in accordance with the priorart. As shown in FIG. 1, the aircraft interior 10 includes a pluralityof elongated frame members 14, and a plurality of isolation mounts 16are attached to each frame member 14. An enlarged isometric view of oneof the isolation mounts 16 is shown in FIG. 2. The isolation mount 16includes a mounting plate 18 having a pair of elongated slots 20disposed therethrough. A floating nut 21 is clipped to the mountingplate 18 near each of the elongated slots 20. Mounting arms 22 (only onevisible) extend from the mounting plate 18 along the sides of the framemember 14 and are secured to the frame member 14 by a fastener 24 (e.g.a rivet, screw, etc.). During assembly, a wall panel 12 is positionedbeside the mounting plate 18, with a pair of hole 24 in the wall panel12 aligned with the floating nuts 21. A mounting screw 26 is then passedthrough each hole 24 and secured to the corresponding floating nut 21,securing the wall panel 12 to the frame member 14.

[0004] Although desirable results have been achieved using the prior artpanel mounting system shown in FIGS. 1 and 2, some drawbacks have beennoted. For example, for installation of wall panels 12 into the aircraftinterior 10, each wall panel 12 typically uses about eighty parts tosecure into position, including ten isolation mounts 16 with twofasteners 24 per isolation mount 16, two floating nuts 21 per isolationmount 16, eight mounting screws 26, and various other components. Inaddition, the process of installing the wall panels 12 using the priorart installation may involve multiple tools and more than one person toaccomplish. Consequently, there is an unmet need to reduce the number ofparts, tools, and personnel, and associated expenses to install wallpanels within the aircraft interior.

SUMMARY OF THE INVENTION

[0005] The present invention is directed to apparatus and methods forattaching wall panels to support structures. Apparatus and methods inaccordance with the present invention may advantageously provide asimplified, more efficient method for attaching panels to supportstructures, thereby improving the efficiency and reducing the expenseinvolved in the installation process. The inventive apparatus andmethods may also inhibit the transmission of structure-borne vibrationfrom the support structure to the wall panels.

[0006] In one embodiment, an apparatus for attaching a panel to anadjoining structure includes a first member and a second member. Thefirst member is adapted to be coupled to the adjoining structure, andhas a first elongated coupling member. The second member has a headportion and a base portion. The head portion has at least one slotdisposed therein that is adapted to receive an edge portion of thepanel. The base portion includes a second elongated coupling memberadapted to be coupled to the first elongated coupling member.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The preferred and alternative embodiments of the presentinvention are described in detail below with reference to the followingdrawings.

[0008]FIG. 1 is an isometric view of an aircraft interior prior toinstallation of wall panels in accordance with the prior art;

[0009]FIG. 2 is an enlarged isometric view of an isolation mount of theaircraft interior of FIG. 1;

[0010]FIG. 3 is an exploded end elevational view of a panel mountingassembly in accordance with an embodiment of the invention;

[0011]FIG. 4 is an enlarged elevational view of one of the attachmentassemblies of the panel mounting assembly of FIG. 3;

[0012]FIG. 5 is an isometric, partial sectional view of the panelmounting assembly of FIG. 3 in an assembled position;

[0013]FIG. 6 is an enlarged end elevational view of an attachmentassembly in accordance with an alternate embodiment of the invention;

[0014]FIG. 7 is an enlarged end elevational view of an attachmentassembly in accordance with yet another embodiment of the invention;

[0015]FIG. 8 is an isometric, partial sectional view of a panel mountingassembly in accordance with a further embodiment of the invention; and

[0016]FIG. 9 is a side elevational view of an aircraft having wallpanels installed using a panel mounting assembly in accordance with theinvention.

DETAILED DESCRIPTION OF THE INVENTION

[0017] The present invention relates to apparatus and methods forattaching wall panels to support structures. Many specific details ofcertain embodiments of the invention are set forth in the followingdescription and in FIGS. 3-9 to provide a thorough understanding of suchembodiments. One skilled in the art, however, will understand that thepresent invention may have additional embodiments, or that the presentinvention may be practiced without several of the details described inthe following description.

[0018]FIG. 3 is an end elevational view of a panel mounting assembly 100in an exploded (or disassembled) position in accordance with anembodiment of the invention. As shown in FIG. 3, the panel mountingassembly 100 includes a plurality of attachment assemblies 110. Eachattachment assembly 110 includes a support member 112 that is coupled toan adjoining frame member 14, and a mounting member 114 that is coupledto an edge portion 116 of a panel 118. In one embodiment, for example,the frame member 14 may be part of an aircraft airframe, and the panel118 may be an interior wall panel of a passenger compartment of theaircraft.

[0019] As further shown in FIG. 3, a mounting layer 113 may be disposedbetween the support member 112 and the frame member 14. The mountinglayer 113 may be formed of any desirable material, such as anelastomeric material or other material suitable for damping oreliminating vibrations that may otherwise be transmitted from the framemember 14 to the support member 112. In one particular embodiment, themounting layer 113 may be formed of an elastomeric materialcharacterized by one or more of the following parameters: an elongationbetween 350% to 500%, a hardness durometer (D) between approximately 50to 60, and a modulus of approximately 90,000 to 150,000 psi. In furtherembodiments, the mounting layer 113 may be formed of acommercially-available material known as HYTREL®, a thermoplasticelastomer (TPE), a siloxane compound, a modified silicone, or any othersuitable material or combination of materials.

[0020]FIG. 4 is an enlarged elevational view of one of the attachmentassemblies 110 of the panel mounting assembly 100 of FIG. 3. As shown inFIG. 4, the support member 112 has an elongated channel 120 disposedtherein. The channel 120 is bounded on either side by a sidewall member122. In this embodiment, a retaining member 124 projects inwardly froman inner surface of each sidewall member 122 into the channel 120.Similarly, a mounting member 126 projects outwardly from an outersurface of each sidewall member 122. A first securing member (orfastener) 128 is disposed on each mounting member 126.

[0021] With continued reference to FIG. 4, the mounting member 114includes a base portion 130 and a head portion 132. The base portion 130projects outwardly from the head portion 132 and is adapted to engagewith the elongated channel 120, as described more fully below. In thisembodiment, the head portion 132 has a pair of slots 134 disposedtherein. The slots 134 are disposed on opposing sides of the headportion 132 and are adapted to fittingly receive the edge portion 116 ofthe panel 118.

[0022] As further shown in FIGS. 3 and 4, the panel mounting assembly100 may further include an insulation assembly 140 having a shell member142 adapted to form a recess 144. An insulating material 146 may beformed in the recess 144. Each end 148 of the shell member 142 mayinclude a second securing member 150 that is adapted to be coupled tothe first securing member 128 of the support member 112. Thus, eachattachment assembly 110 may be used to attach both the panel 118 and theinsulation assembly 140 to the frame member 14.

[0023] It will be appreciated that the first and second securing members128, 150 may be any type of suitable coupling members. In oneembodiment, for example, the first and second securing members 128, 150may be so-called tongue-in-groove or ZIP-LOC® type securing members asshown in FIGS. 3 and 4. In alternate embodiments, the first and secondsecuring members 128, 150 may be snaps, hook-and-loop fastener strips(e.g. VELCRO® strips), adhesive, rivets, screws, or any other suitablesecuring or fastening devices.

[0024]FIG. 5 is an isometric, partial sectional view of the panelmounting assembly 100 of FIG. 3 in an assembled position. In theembodiment shown in FIG. 5, two panels 118 and two insulation assemblies140 are mounted onto three frame members 14 using three attachmentassemblies 110. The panel mounting assembly 100 may be assembled byattaching the support member 112 of each attachment assembly 110 to oneof the frame members 14. The attachment of the support member 112 to theframe member 14 may be accomplished in any desired manner, including,for example, by rivets, screws, adhesive, thermal bonding, or using anyother suitable attachment mechanism. As set forth above, the mountinglayer 113 may be positioned between the frame member 14 and the supportmember 112 to reduce vibration, or alternately, the mounting layer maybe omitted. In another embodiment, the support member 112 may beintegrally formed with the frame member 14. The insulation assemblies140 may then be installed by coupling the second coupling members 150 onthe insulation assemblies 140 (FIG. 4) with the first coupling members128 on the support member 112. In alternate embodiments, the insulationassemblies 140 may be coupled to the support members 112 prior to theirattachment to the frame members 14, or alternately, the insulationassemblies 140 may be omitted.

[0025] The mounting members 114 may then be coupled to the panels 118 byinserting the edge portions 116 of the panels 118 into the slots 134.The mounting members 114 may then be coupled to the support members 112by engaging the base portion 130 of each mounting member 114 into thechannel 120 of the corresponding support member 112. Alternately, thepanels 118 may be coupled to the mounting member 114 after the mountingmember 114 is coupled to the support member 112, or a combination ofthese alternate possibilities may be employed.

[0026] The base portion 130 may be engaged into the channel 120 in avariety of suitable ways. For example, in one embodiment, the baseportion 120 may be engaged into the channel 120 by slideably engagingthe base portion 130 into an open end 121 of the channel 120 (FIG. 5).The base portion 130 may then be slid along a longitudinal axis 123 ofthe channel 120 until the mounting member 114 is properly positionedwith respect to the support member 112 (e.g. aligned with the supportmember 112). Alternately, the mounting member 114 may be positioned nearthe support member 112, and the base portion 130 may simply be snappedor force-fit into the channel 120 of the support member 112.

[0027] In the assembled position, the base portion 130 may be adapted toengage with the cross-sectional shape of the channel 120 such that,under normal operating conditions, the base portion 130 is substantiallyconstrained within the elongated channel 120 from movement relative tothe support member 112 in directions other than along the longitudinalaxis 123 of the channel 120. In the embodiment shown in FIGS. 3-5, forexample, the base portion 130 is engaged into the channel 120 but isconstrained from movement out of the channel 120 by the relativelynarrow portion of the cross-sectional shape of the channel 120 createdby the inwardly-projecting retaining members 124. The ends of thechannel 120 may then be blocked, or the base portion 130 otherwisesecured within the channel 120, to prevent undesired movement of thebase portion 130 along the longitudinal axis 123 of the channel 120.

[0028] The panel mounting assembly 100 advantageously provides asimplified, more efficient method for attaching panels 118 to adjoiningsupport structures 14. The number of parts involved in the installationis substantially decreased, along with the number of tools required forthe operation, in comparison with the prior art. Overall, the efficiencyof the process of installing panels within vehicles, including withinthe passenger compartments of aircraft, may be improved, and the amountof labor and expense involved in the operation reduced. The panelmounting assembly 100 may also reduce or eliminate structure-bornevibration that would otherwise be transmitted from the supportstructures 14 to the panels 118, which may further enhance passengercomfort within, for example, the interior of a passenger aircraft.

[0029] It will be appreciated that the invention is not limited to theparticular embodiment of the attachment assembly 110 shown in FIGS. 3-5,and that the channel 120 and the base portion 130 may have a widevariety of suitable configurations. For example, FIGS. 6 and 7 showenlarged, end elevational views of attachment assemblies in accordancewith alternate embodiments of the invention. In the embodiment shown inFIG. 6, the attachment assembly 210 includes a support member 212 havingsloping sidewalls 222 that form a channel 220 having a partial (ortruncated) triangular cross-sectional shape. Similarly, the mountingmember 214 includes a correspondingly-shaped base portion 230.Furthermore, as shown in FIG. 7, the attachment assembly 310 may includea support member 312 that includes a channel 320 having across-sectional shape with a narrow portion 321 that is located at aposition between a bottom wall 323 of the channel 320 and an outeropening 325 of the channel 320. The mounting member 314 may then includea base portion 330 having a corresponding cross-sectional shape. Ofcourse, a wide variety of suitable cross-sectional shapes of channelsand base portions may be used in accordance with the teachings of thepresent invention.

[0030] It should also be noted that the mounting assembly may be furthermodified such that the channel is disposed in the mounting member andthe base portion that engages into the channel is part of the supportmember. For example, with reference to the embodiment shown in FIG. 7,the first member 314 may be coupled to an adjoining frame member 14(FIGS. 3-5), and the second member 312 may include one or more slots 334(shown in phantom lines) that engage with an edge portion of a panel118. Thus, the second member 312 may be engaged onto the first member314 in the manner described above to attach a panel 118 to the framemember 14.

[0031]FIG. 8 is an isometric, partial sectional view of a panel mountingassembly 400 in accordance with another embodiment of the invention. Inthis embodiment, a pair of attachment assemblies 410 are mountedtransversely to a plurality of frame members 14, and a panel 118 ismounted therebetween. Thus, the above-noted advantages of the inventionmay be realized in a panel mounting assembly 400 having attachmentassemblies 410 that are transverse (e.g. perpendicular or otherwise) tothe adjoining supporting members.

[0032] Although the above-noted embodiments have been described withreference to attachment to elongated frame members 14, the invention isnot limited to operation with such members, and in fact can be used toattach panels to virtually any type of support structure, including, forexample, flat walls or non-vertical frame members. The attachment andmounting assemblies of the present invention may be employed withsupport structures of virtually any design, construction, or materialcomposition, including, for example, support structures made ofaluminum, steel, thermoplastics, composites, or any other desiredmaterials.

[0033]FIG. 9 is a side elevational view of an aircraft 500 having wallpanels 118 installed using a panel mounting assembly 502 (not visible)in accordance with the invention. All of the components of the aircraft500, other than the panel mounting assembly 502 of the presentinvention, are of generally known construction and, for the sake ofbrevity, will not be described in detail herein. For example, theaircraft 500 includes one or more propulsion units 504, wings 506 (orother lifting surfaces), a tail assembly 508, a landing assembly 510, acontrol system 512 (not visible), and a host of other systems andsubsystems that enable proper operation of the aircraft 500. Theaircraft 500 shown in FIG. 9 is generally representative of a commercialpassenger aircraft, including, for example, the 737, 747, 757, 767, and777 models commercially-available from The Boeing Company. The apparatusand methods disclosed herein, however, may also be employed in any othertypes of aircraft, such as rotary aircraft or manned military aircraft,including those described, for example, in The Illustrated Encyclopediaof Military Aircraft by Enzo Angelucci, published by Book SalesPublishers, September 2001.

[0034] While certain embodiments of the invention have been illustratedand described, as noted above, many changes can be made withoutdeparting from the spirit and scope of the invention. Accordingly, thescope of the invention is not limited by the disclosure of the exemplaryembodiments, but rather, the invention should be determined entirely byreference to the claims that follow.

What is claimed is:
 1. An apparatus for attaching a panel to anadjoining structure, the apparatus comprising: a first member having afirst elongated coupling member, the first member being adapted to becoupled to the adjoining structure; and a second member having a headportion and a base portion, the head portion having at least one slotdisposed therein, the slot being adapted to receive an edge portion ofthe panel, the base portion having a second elongated coupling memberadapted to be coupled to the first elongated coupling member.
 2. Theapparatus of claim 1, wherein the first elongated coupling memberincludes an elongated channel having at least one open end, and whereinthe second elongated coupling member includes an elongated projectionthat is engageable into the open end and slideable along a longitudinalaxis of the elongated channel, the elongated projection beingsubstantially constrained within the elongated channel from movementrelative to the first member in directions other than along thelongitudinal axis.
 3. The apparatus of claim 2, wherein the elongatedchannel is defined by a pair of side surfaces, a bottom surfaceextending between the side surfaces, and an outer opening opposite fromthe bottom surface, the side surfaces and bottom surface defining across-sectional shape having a narrowed portion that is spaced apartfrom the bottom surface.
 4. The apparatus of claim 2, wherein theelongated channel is defined by a pair of side surfaces, a bottomsurface extending between the side surfaces, and an outer openingopposite from the bottom surface, at least one of the side surfacesincluding a retaining member projecting inwardly into the elongatedchannel.
 5. The apparatus of claim 2, wherein the first member isadapted to be coupled to the adjoining structure such that thelongitudinal axis of the elongated channel is oriented at leastpartially along the adjoining structure.
 6. The apparatus of claim 2,wherein the first member is adapted to be coupled to the adjoiningstructure such that the longitudinal axis of the elongated channel isoriented transverse to the adjoining structure.
 7. The apparatus ofclaim 1, wherein the second elongated coupling member includes anelongated channel having at least one open end, and wherein the firstelongated coupling member comprises an elongated projection that isengageable into the open end and slideable along a longitudinal axis ofthe elongated channel, the elongated projection being substantiallyconstrained within the elongated channel from movement relative to thesecond member in directions other than along the longitudinal axis. 8.The apparatus of claim 1, wherein the head portion has first and secondslots disposed in opposing sides thereof.
 9. The apparatus of claim 1,wherein the head portion includes a substantially T-shaped portionhaving first and second outwardly extending portions, each outwardlyextending portion having a slot disposed therein.
 10. The apparatus ofclaim 1, wherein the first member includes first and second sidewalls,the elongated channel being disposed between inner surfaces of thesidewalls, at least one of the first and second sidewalls having anouter surface including a mounting arm projecting outwardly from thesidewall, the mounting arm including a securing member.
 11. Theapparatus of claim 10, wherein the securing member includes atongue-in-groove securing member.
 12. The apparatus of claim 10, furthercomprising an insulation assembly coupled to the securing member.
 13. Anassembly for attaching a panel to a structure, the assembly comprising:a panel having a first edge portion; a support member having anelongated channel disposed therein; and a mounting member having a headportion and a base portion, the head portion having at least one slotdisposed therein, the first edge portion of the panel being disposed inthe slot, the base portion being engaged into the elongated channel andsubstantially constrained within the elongated channel from movementrelative to the support member in directions other than along theelongated channel.
 14. The assembly of claim 13, wherein the elongatedchannel has at least one open end, the base portion of the mountingmember being slideably engaged into the elongated channel through theopen end.
 15. The assembly of claim 13, wherein the elongated channel isdefined by a pair of side surfaces, a bottom surface extending betweenthe side surfaces, and an outer opening opposite from the bottomsurface, the side surfaces and bottom surface defining a cross-sectionalshape having a narrowed portion that is spaced apart from the bottomsurface.
 16. The assembly of claim 13, further comprising a supportstructure, the support member being coupled to the support structure.17. The assembly of claim 16, wherein the support member is integrallyformed with the support structure.
 18. The assembly of claim 16, furthercomprising a vibration damping member disposed between the supportmember and the support structure.
 19. The assembly of claim 16, whereinthe support structure includes an elongated frame member, the supportmember being coupled to the elongated frame member such that alongitudinal axis of the elongated channel is oriented at leastpartially along the elongated frame member.
 20. The assembly of claim16, wherein the support structure includes an elongated frame member,the support member being coupled to the elongated frame member such thata longitudinal axis of the elongated channel is oriented at leastpartially transverse to the elongated frame member.
 21. The assembly ofclaim 13, further comprising a support structure, the support memberbeing coupled to the mounting member.
 22. The assembly of claim 13,wherein the head portion includes a substantially T-shaped portionhaving first and second outwardly extending portions, each outwardlyextending portion having a slot disposed therein.
 23. An aircraftcomprising: a support structure; and a wall assembly operatively coupledto the support structure, the wall assembly including: a panel having afirst edge portion; a first member having a first elongated couplingmember, the first member being coupled to the support structure; and asecond member having a head portion and a base portion, the head portionhaving at least one slot disposed therein, the first edge portion of thepanel being disposed in the slot, the base portion having a secondelongated coupling member adapted to be coupled to the first elongatedcoupling member.
 24. The aircraft of claim 23, wherein the firstelongated coupling member includes an elongated channel having at leastone open end, and wherein the second elongated coupling member includesan elongated projection that is engageable into the open end andslideable along a longitudinal axis of the elongated channel, theelongated projection being substantially constrained within theelongated channel from movement relative to the first member indirections other than along the longitudinal axis.
 25. The aircraft ofclaim 24, wherein the elongated channel is defined by a pair of sidesurfaces, a bottom surface extending between the side surfaces, and anouter opening opposite from the bottom surface, the side surfaces andbottom surface defining a cross-sectional shape having a narrowedportion that is spaced apart from the bottom surface.
 26. The aircraftof claim 24, wherein the elongated channel is defined by a pair of sidesurfaces, a bottom surface extending between the side surfaces, and anouter opening opposite from the bottom surface, at least one of the sidesurfaces including a retaining member projecting inwardly into theelongated channel.
 27. The aircraft of claim 24, wherein the firstmember is adapted to be coupled to the adjoining structure such that thelongitudinal axis of the elongated channel is oriented at leastpartially along the adjoining structure.
 28. The aircraft of claim 24,wherein the first member is adapted to be coupled to the adjoiningstructure such that the longitudinal axis of the elongated channel isoriented transverse to the adjoining structure.
 29. The aircraft ofclaim 24, wherein the second elongated coupling member includes anelongated channel having at least one open end, and wherein the firstelongated coupling member includes an elongated projection that isengageable into the open end and slideable along a longitudinal axis ofthe elongated channel, the elongated projection being substantiallyconstrained within the elongated channel from movement relative to thesecond member in directions other than along the longitudinal axis. 30.The aircraft of claim 23, wherein the head portion includes asubstantially T-shaped portion having first and second outwardlyextending portions, each outwardly extending portion having a slotdisposed therein.
 31. A method of attaching a panel to an adjoiningstructure, the method comprising: providing a first member having anelongated channel disposed therein, the elongated channel having atleast one open end; providing a second member having a head portion andan elongated base portion, the head portion having at least one slotdisposed therein; coupling one of the first and second members to theadjoining structure; engaging the elongated base portion into theelongated channel; and engaging an edge portion of the panel into theslot disposed in the head portion.
 32. The method of claim 31, whereinproviding a first member having an elongated channel disposed thereinincludes providing a first member having an elongated channel disposedtherein, the elongated channel having at least one open end; and whereinengaging the elongated base portion into the elongated channel includesslideably engaging the elongated base portion into the open end andalong a longitudinal axis of the elongated channel, the base portionbeing substantially constrained within the elongated channel frommovement relative to the first member in directions other than along thelongitudinal axis.
 33. The method of claim 31, wherein the first memberis coupled to the adjoining structure such that the longitudinal axis ofthe elongated channel is oriented at least partially along the adjoiningstructure.
 34. The method of claim 31, wherein the first member iscoupled to the adjoining structure such that the longitudinal axis ofthe elongated channel is oriented transverse to the adjoining structure.35. The method of claim 31, wherein the second member is providedwherein the head portion has first and second slots disposed in opposingsides thereof.
 36. The method of claim 31, wherein the second member isprovided wherein the head portion includes a substantially T-shapedportion having first and second outwardly extending portions, eachoutwardly extending portion having a slot disposed therein.
 37. Themethod of claim 31, wherein the first member includes first and secondsidewalls, the elongated channel being disposed between inner surfacesof the sidewalls, at least one of the first and second sidewalls havingan outer surface including a mounting arm projecting outwardly from thesidewall, the mounting arm including a securing member, and wherein themethod further comprises engaging an insulating assembly with thesecuring member.